The Lunar Grey Mk1 Hybrid Project

[Chip-mk1]

Dont get too obsessed with every little pointless detail on a car that if you are going to start learnign to do trackdays in it might get wrecked anyway, get some use out of it even if its only 90% how you want it.

 

[Zmaster2k]

Aye know what your saying

Just my toy for the minute lol

 

[Zmaster2k]

So working on my dash some more today


Take dummy dash the f**ked template
!
Make template of binical

Transfer template onto carbon fibre



Now next step will be attachinh into the dash somthing like this

Obviously not this one…. Its broken lol

 

[Djw John]

Nice, you gonna recess the digi dash flush or sit it proud?

 

[Zmaster2k]

Think i'll just sit it proud! too much fannying about to get it recessed! lol

 

[Zmaster2k]

So started smoothing over dash centre today…fiberglass dossnt stick to French plastic. But working so far





Should look good when flocked!

 

[Zmaster2k]

Bit more progress now!


Splitter on, thanks padlar!


Before

After

Arty farty

Bit more dash work!


OK so set about completing the dash2 mount.


Had to put the binical on the belt sander to make it flat! As its moulded to the clocks.


First of all set about mounting the carbon back to the binical used PVC blocking.

And some m6 coach bolts.

Looks pretty good!

Finally mounted dash2

 

[Chip-mk1]

Cool stuff.

 

[dmallett]

oooosh. love those digital dashs

 

[Zmaster2k]

Cheers lads!

 

[Daniel]

I wish I had your time/patience/skill/place to keep a car.

Every time I look into this thread I die a bit inside.

 

[Zmaster2k]

FLOL! yeah but im an obsessive compulsive... depressed as ive not driven anything with some power for a while

 

[Zmaster2k]

Removed the Oldloom today

Left the enginebay looking like this

Looks so clean without the wiring!


New radiator and Omex wiring loom for beaniesport to chop up lol

Probably going to sell this as won’t be required with itbs

Got bored and fitted excess carpet to garage, can see box on right full of old wiring for beanie sport

 

[Djw John]

That pic of the bay really highlights how wrong the colour was!

Good wee bit more progress, and lots just around the corner

 

[Zmaster2k]

It Does a touch doesn't it! lol!

 

[Chip-mk1]

Should be a fun car on bodies

Let me know if you need me to source you a quaiffe diff cheaper than retail, that will be the next thing holding it back now.

If you want you can pop over to Dan's on sunday near glasto and drive mine before and after me and him fit the quaiffe just to show you what a difference it makes.

 

[Zmaster2k]

Will check the calendar!

 

[Zmaster2k]

Yes that’s right, finally I’ve removed the distrubutor cap and ht-leads.


The Omex can take care of this for me so now I need a newer “wasted spark” coil pack. The RS Clio uses one but requires Ht-leads to each spark plug. After some reading up found out the f7r in the megane uses a wasted spark setup. However unlike the RS Clio its coil pack sits directly on top of the cam cover and connects direct to the spark plugs. Meaning no ht-leads to worry about. This does however mean I must run the megane cam cover…this in my opinion looks better so wassn’t bothered.


Found both parts for sale on owners clubs within the hour…£65 later they were on their way.

New cam cover

Wasted spark coil pack.


So got busy with my spanners once again.

Removed the cam cover and old 1910 (year it was introduced to a production car by Cadilac) ignition system & cam cover.

Modified the coil pack with some old panel fasteners….

Found some washers in black the right size….

Old Setup

New setup!

 

[Djw John]

That does look better mate, nice and tidy.

 

[Zmaster2k]

Its going to look much better when the Jenveys are fitted and i repaint the engine bay...looks a bit odd at the moment.

 

[Zmaster2k]

Centre console Mould making and prototype


So basically I wassnt happy with not having a center panel in the car. So mocked up some ply panels to fit in its place. (this made the dash SOLID)

From this I turned it into a model to make a mould from

Covered this item in release wax and liquid wax…a release agent.


Then covered in gel coat.

This was left to harden over night
Then covered in resin and talc filler and then fiberglass matting

Left to harden overnight then another layer of the same

Then left to harden overnight again 3 layers later its about this thick.

Then “simply” pop the mould off the model…

Screwdriver and hammer required! Leaves you with this.

Run it through the band saw and trim off the rough edges….leaving excess… And then sand with 320grit and 400grit

Then add back plate and add a few layers of wax and liwuid wax (i did 4 but the more the bettrr) layer of gel coat and leave to go tacky… The layer in some material


Happened to have some carbon laying about… not enough but will do on the prototype

Layered it in as I’ve never used it in mould making… So had enough for first layer… Then used low weight fiberglass as replacement (use this normally)

I’ve done 3 layers of fiberglass on top…


Left for a day between layers.


Then simply demould….again…screwdriver required…more wax next time


Removed back plate
And trimmed fiberglass overlap with very sharp chisel

Then popped out of mould

You can see the carbon weave. But I’ve been inconsistent with my gel coat so I have some milkyness… and a few air bubbles...Will be more vigilant with mk2…

But fairly chuffed if this was flocked or painted you would never know.

an All carbon Mk2 coming soon!....

 

[Djw John]

Nice, credit to you mate, clearly good at your job!

 

[Zmaster2k]

Lol i normally make moulds for Decorative stone! So.. using the mould for a fiberglass item was kinda new ground.. still im quite chuffed... its stroing as hell... only weighs 700g and can support my weight.

 

[ROB91]

I've just read this from start to finish, and what a build. Good effort and Lunar Grey is just an amazing colour.

 

[Zmaster2k]

Thanks rob appreciate the comments

 

[Nafoff]

good work mate, now get it sorted ready to transport

 

[Zmaster2k]

lol cant believe YOUR telling me to hurry up Neil! PMSL

 

[Zmaster2k]

So had a few mins so thought it was a good idea to combine all my interior bits together for trial fitment.


Pics

Then thought I’d see what they were like in the car.


Passenger side

First gear selected in next set of photos for clearance checking... didnt want to be shifting into 3rd to find my hand hit the panel! (and i forgot to finish my other centre panel which is smoothed over...)

Check out the mirror finish of that panel! lol

Got the Race-Technology Dash2 fitted to the car to see if my modified panel fitted and didnt foul

Overall shot

V chuffed fits as it should and I now feel like I have a more complete interior! Yay!


Just got to make an all carbon mk2 now!

 

[Zmaster2k]

Waved goodbye to the stock inlet and plenum… the polished days are over!


Time for some performance

Looks so empty and bare! Individual throttle bodies will soon cure that! Yay

 

[Nafoff]

lol cant believe YOUR telling me to hurry up Neil! PMSL

pot kettle black,

 

[Chip-mk1]

Should be a fun little car on bodies, although I think eventually you will grow to hate the lag, but its PERFECT for getting in a few trackdays and learning the car properly, then at a later date maybe still proceed with your audi turbo plans.

 

[Zmaster2k]

pot kettle black,

]

he he he

Should be a fun little car on bodies, although I think eventually you will grow to hate the lag, but its PERFECT for getting in a few trackdays and learning the car properly, then at a later date maybe still proceed with your audi turbo plans.

Yeh im in two minds about that! May just go Boosted f4r!...Seems like another good option! lol

 

[Chip-mk1]

]Yeh im in two minds about that! May just go Boosted f4r!...Seems like another good option! lol

Depends how hard and how often you are going to use it, and how deep your pockets are.
Its quite dear to do well, and still a fragile gearbox unless you get a VAG box on there or whatever, at which point may as well save some money and do the engine too?

Watch my ph1 turbo vids from bedford though if you want to get corrupted, lol

You really need to pop over for a spin in it sometime mate, next meet or something.

 

[Zmaster2k]

Yeah saw the bedford vids looked rapid! The M3 Video was just pure hilarity!

 

[Zmaster2k]

So chopped the steering cowling up to make it fit better with the mk2 dash!


Seems to of worked out alright!

 

[Chip-mk1]

Interesting blend of old and new. Would look good all same colour. Flocked for example.

 

[AdamAnderton]

cars looking really good, just had a read through the whole thread start to hear good read so far can't wait to see whats next
wish i could find some time to continue on my mk1 f4r track car, someday soon hopefully

 

[Zmaster2k]

Interesting blend of old and new. Would look good all same colour. Flocked for example.

Yup going to send it all away for flockin' Know anybody?

cars looking really good, just had a read through the whole thread start to hear good read so far can't wait to see whats next
wish i could find some time to continue on my mk1 f4r track car, someday soon hopefully

Yeah common Adam! Been ages since ive seen yours!


Sorry for the shite update lads!

 

[Chip-mk1]

Yes mate, raj@autoflock is your man. Excellent work and sensible prices.

 

[Nafoff]

Yes mate, raj@autoflock is your man. Excellent work and sensible prices.

or getflocked based in taunton